Press for pressing laminated materials



Aug. 13, 1957 F. LYIJYNEN 2,802,510

' PRESS FOR PREssING LAMINATED MATERIALS Filed Nov. '7, 1951 2 sheets-sheet 1 i mzl" (g5 IN VEN TOR. ed lg ne.

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)7 7 Tan/VE Aug. 13,1957 F. I YUYNEN PRESS -FoR4 PREssING 4Lmmnuvman MATERIALS l 2 Sheets- Sheet 2 Filed Nov. '7, 1951 INVENTOR.v 77rd gne/z FTTIV/VEK nited States `Patent- Mich., assigner, by mesne `assigna corporation of Dela- This invention relates to a laminated upholstered structure or panel and to a method and apparatus for manufacturing the same, the structure being particularly though not exclusivelyadapted for covering automobile seats and seat-backs.

Ari object of the invention is to provide an improved flexible laminated upholstery structure comprising a padding layer interposed between cover and foundation layers', the layers being compacted and bondedtogether along a marginal strip and also along a plurality of generally parallel grooves depressed into the cover layer and spaced by upholstered areas extending transversely to said'marginal strip. Y

Preferably in this construction, the marginal strip is arranged so as to lie adjacent an edge of theseat or seatbaclcto be covered and is accurately trimmed along its outer edge to a uniform width to provide la compacted triplethickness outer guide ledge for 'arsewing machine guide or follower. The adjacent ends of the upholstered areasterminate along a line parallel to said outerguide edge, fwhich may thus be employed to guide a sewingmachine follower and to facilitate the sewing of `a facing cloth to the marginal strip. The facing cloth is provided to cover side portions `of the seat or seat-back and is arranged on the cover layer of thc'laminated structure orpanel with an edge j marginal strip and directed edgewise outward theref. The facing cloth is then sewed to the marginal strip along the aforesaid line of termination of the upholstered areas',

portion overlying the aforesaid the outer guide edge of the strip parallel tosaid line permitting the sewing to be accomplished quickly and accurately to aord a neat seam. Thereafter the facing cloth is folded outward along the seam to cover the latter and `the marginal strip and to comprise a side covering for the seat or seat-back. t

Another `object is to provide an improved laminated structure of the foregoing nature wherein the several layers are compacted and bonded together along the j grooves and marginal strip `as aforesaid by means of a comparatively flexible or pliable bonding agent applied as an aqueous varnish comprising a mixture of a rubber cement and a lpartially polymerized phenolic resin, the rubber cement comprising a major portion of the mixture by weight and consists of approximately three-fourths latex and one-fourth rosin or colophony, the varnish being applied to the layers at the regions to be bonded together and `thereafter cured to complete the polymerization of the resin by the application of heat and pressure during the process of compacting the grooves and marginal strip.

In the fabrication of a laminated cover structure or panel of the foregoing nature, wherein the cover layer is depressed into the underlying layers along a plurality of generaliy parallel grooves extending transversely to a marginal -stripalso depressed into the coverlayer, `the cover` layer seen along any section line` through the upholstered areas and parallel to the marginal strip will haveagenerally scalloped appearance, Awhereas the cover layerwill be straight along a similar parallel section line 2,802,510 Patented Aug. 13, 1957 2 through the marginal strip. 4Inasrnuch as the samepamount of cover-layer material must exist along either section line, difficulty has been experienced heretofore in the fab`r`iciar tion of such a structure without causingV gathering and puckering of excess material of the cover layer along theI marginal strip. j

V'Other important objects of thepresent invention are to provide an `improved method or process for fabricating laminated structure of the foregoing nature so as to eliniinate or render unobjectionable the gatheringror puckering of the `cover layer along the marginal or border strip, and to provide a simple eicient'apparatus for carrying out the improved method. l l In brief the method comprises arranging the unpres'sed layers in their superimposed relation with the cover l'yei' arranged loosely against the lower die members,l andprogressively pressing the grooves into the cover and padding layers so as to compact and bond the layers together at the regions of the grooves thereby leaving the intervening impressed areas in the form of parallel pipes, orupholstered portions. Simultaneously during the pressing op eration the marginal portions ofk the layers yare progres'- sively pressed or compacted to provide a at compacted border or marginal strip. extending continuously around foursides of the panel. The progressive pressing of the st rip occurs, in delayed relation with respect to the progressive pressing of the grooves. Thus, as excess material along the length ofthe marginal or border strip tends to form `wrinkles or` gatherings upon formation of 'the grooves, theA wrinkles or'gatherings are distributed uniformly along the length of the strip by the progressively increasing pressure applied to compact lthe strip and are thereby smoothed out and'endered unohjectionable.` In one application of the methodthe pressure appliedlprogressively toform the marginal strip is directed both to- Wd the CV'er lyr ld OltWifd end WiSe of the OV'S during the initial pressing operation, so as to pull .the edge of the cover la'yer outward. and to4 facilitate the uniform distribution of wrinkles orgatherings tending toform along thatedge. f` j n I v Another object of theAV inventionris to provide an apparatus for carrying,outmtheforegoing process comprising opposed upper and lower press jaws or members adapted to receive the unp'r'essed laminated material therebetween and being "relatively movable toward 'each other in the pressing operation to press the material therebetween, the lower press member havingaplurality of generally parallel raised depression forming ribs arranged to opposite the upper press member and press said grooves into thecove'r layer during the pressing operation. A swinging vpress or die member having an edge-pressing element extending transversely to said ribs is pivoted on a portion of thepress tixed with respect tothe lower press member to swing" the edge-pressing lelement upward in opposition to the upper press member and into pressing engagement with the cover layer to form Said depressed marginal strip. In this construction, means'. are also provided for' swinging theedge pressing element progressively against the cover layer simultaneously but in delayed relation to progressive rela'- tive movement of4 said upper and lower press members toward each other in the pressing operation, thereby to distribute uniformly along the length. of the strip any wrinkles or gatherings tendingto form as a result of the progressive formation of said parallel grooves.

A more specilic object is to provide an apparatus of lthe foregoing nature wherein therswinging press member is pivoted on` the lower press member to. swing about an axis located parallel to said strip and edge pressing element and also located endwise outward ofrsaid ribs and below the upper edges of the latter. The edge-pressing element isv arranged inward ofthe axis' so as to swing upward and outward with respect tothe ribs into pressing engagement with the cover layer, thereby to pull" the latter outward by frictional engagement therewith during the pressing operation. Extending Aoutward from the axis of the swinging press member is an arrrijof the 'latter arranged -to be engaged V by theupper press member and tc befswung downward thereby upon relative movement of the upper and lower press members 'toward each other. in the press operation, thereby to cause the aforesaid upward and outward swingingof the inner edge-pressing element into` pressing. engagement withV thecover layer to form the marginal strip. Y

Another object is to provide such a construction wherein a cut-off edge is carried Vby the swinging press member adjacent and outward of the edge-pressing element, so as to swing upward and outward therewith in the pressing operation. Y The cut-E edge projects upwardof the edgepressing element at a final pressing position, so as to pierce the laminated structure alongthe length of the depressed marginal strip and trim the latter to form the aforesaid outer guide edge for a sewing machine guide orfollower. e Likewise the cut-off edge, projecting upward of the edge pressing element, frictionally engages the cover layer to drag the latter outward during movement of the lswinging pressmember to the final pressing position, so as to facilitate uniform distribution of wrinkles or gatherings along the strip in the manner above outlined.

Other objects of this invention will appear in the folaseasld lowingdescription and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the severalviews.

Fig. 1 is a perspective viewof an automobile seat and seat-back covered by a laminated upholstery panel embodyingA the present invention.

Fig. 2 is a plan view of the panel prior to being sewed to the facing cloth. l Fig. 3 is a fragmentary exploded sectional view showing the component layers of the laminated structureprior to being bonded together. Fig. 4 isa fragmentary vertical sectional view through a press apparatus, showing the latter at the pressing position inthe process of formingV the grooves and a portion of the marginal strip parallel to the grooves.V

Fig. 5 is a fragmentary sectional view transverse to an edge of the laminated'structure, illustrating the processof sewing the facing cloth to the marginal strip.

.Y Fig. .6 is a fragmentary vertical section taken through the press Vapparatus-in the direction of the arrows along the line 6 -6 of Fig. 8, illustrating the method of ar- .I .ranging the laminatons in the press prior to theV bonding operation. Y

Fig. 7 is a view rsimilar to Fig..6, but showing the press apparatus at the pressing position .during formation of the panel.

Fig.` 8 is a fragmentaryplan view with portions broken away, showing the lower press members adjacent an edge of the laminated material overlying the `ends .of the depression forming ribs, taken in the directionv of the arrows along the line 8 8 of Fig. 9. Y Y

Fig. 9 is a vertical section taken in the direction of Athe arrows along the line 9-9 of Fig. 8, showing the press apparatus vin the loading position as shown in Fig. 6.

Figl 10 is a vertical sectional view similar to Fig. 9, but .showing the press apparatus at the pressing position as illustrated in Fig. 7.

It is to be understood that the invention is not limited in its application-to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various Ways. Also it is to be understood that theV phraseology Vor terminology employed herein is for the purpose of description and not of limitation. Y

VReferring to the drawings, a panel structure embodying the present invention is illustrated by way of example comprising a two part cover for an automobile seat and seat-back structure, Fig. 1, including a laminated upholstered part indicated generally by the numeral covering Vtheupper surface of the seat and forward surface of the back, and a facing layer 21 suitably stitched to marginal portions of the upholstered part 20 and applied to cover the vertical sides of the seat and seat-back. The upholstered part 20 may comprise a unitary structure covering both the seat and back, or as illustrated in Fig. 2, may comprise one portion dimensioned to cover the seat and a separate similar but larger portion formed to cover the back. Also as illustrated in Figs. l and 2, the layers of the laminated part 20 are compacted at the region of a marginal strip 22 and along a plurality of generally parallel grooves or pattern lines 23 spaced by uncompressed or upholstered areas 24, Vas discussed in detail below.

As indicated in Fig. 3 the laminated part 20 comprises an intermediate padding or upholstery layer 25 of sponge or foam rubber or wadding or the like, interposed between an upper cover layer 26 and lower foundation layer 27. t The latter two layers may comprise any suitable sheeting such as a flexible plastic, cloth,or fabric.

grooves 23 are accomplished between the opposed heated jaws or press members of a suitable press, as for example a hydraulic press having upper and lower platens or press members 28 and 29, Fig. 4. For the purpose of discussion, the lower member 29 'may be considered fixed or stationary and carries a die plate 30 having a plurality of raised'depression forming ribs 31 secured to the plate 30 by screws 32. The ribs 31 extend parallel'to each other for the desired length of the grooves 23 and are formed along their upper edges, which confront the press member 28, so as to press the grooves 23 into the laminated material/during a pressing operation.

The formation of the lateral portions of the marginal strip 22 which are parallel to the grooves 23 offers no particular problem. These portions are formed similarly to the grooves 23 lby means of a pair of lateral ribs 33 parallel to the ribs 371, one secured to the plate 30 by screws 32 along each lateral edge of the die structure. The ,upper press'member 28 is provided with a plane pressing surface confronting the upper ,edges of the ribs 31 and 33 and is movable toward and fromthe latter lin a pressing cycle. ranged between the members 28 and 29 and with the cover layer confronting the ribs 31 and 33, these ribs are depressed into the panel upon downward movement of the member 28 to the pressing position, Fig. 4. Simultaneously the panel layers are bonded together, by means of a bonding agent discussed below, along the lines of heat and pressure applied during the pressing operation. Formation of the portions of the strip 22,

the press operation, the outer edge of the strip 22 is accurately trimmed to a uniform width to provide an outer guide edge for the pumose discussed below.

The bonding substance for bonding the laminations together may be applied either to the foundation layer 27 or to the padding layer 25',` or to both, and is usually somewhat tacky and of a type that will be cured or polymerized by the heat and pressure of the members 28 and 2.9 during the press operation. The bonding substance preferably includes, at least -in part, a thermosetting resin such as a phenol-formaldehyde or aurea-formaldehyde resin in an intermediate stage of reaction when applied to the laminations, so as to be cured or set perma- Thus with the panel material ararea51@ neatly when subjected to the, heat of the pressing operan n for" preltjr ined p 'dY or time. `It is desirable that the onding sulstniel used with upholstery panels foi' seat id back covers be such as to bond the laminatiorspermanently together ale'ng lin`es or areas which are flexible orpliable. This particularly" important with seat or back eishioris"` which are subjected to deforming i distorting" forces due tb 'the weight `o'f the occupant of the seat.` p Thermosetting resins, especially ofthep'li'enolic type, Ywhen used as the bonding medium produce undesirably stiff bonding lines or regions which are comparatively brittle andwhich crack or pucker and-eventually produce ai? unsightly appearance when deformed or bent out of s ape. f I ii accordancewith the present invention, relatively flexible and pliable bndingflines or regions are produced by' mean'sof bonding resin comprising as the principal constituents a rubber-like vbonding substance mixed with the phenolic resin.` As an example, a rubber cement composed principally of approximately three parts of a synthetic or natural rubber or latex and one part of rosin or co'lophony` are utilized. A liquid varnish is ,prepared by mixing this cement and a phenolic resin ina water carrier, the cement and resin being kof the types which are soluble or miscible in water. This resin mixture may comprise, for example, from approximately 5% to. `11% by weight 4of phenolic resin and from approximately 22% "to l28% by weight of rubber cement, the balance of the varnish being water. Such `a bonding mixture, when heatedunder pressure, `will .produce ilexible land pliable bonding lines or areas and will Withstand `the bending orkdeforming forces to which the seat or back-cushionis subjectedby the weight of the occupant. Afterpressing the laminatedpart 20 .and trimming the outer edgeof the strip ,22, the facing cloth `'21 which may comprise V'any suitablefabric, plastic sheet or the like, -issiitably stitched -to the strip 22 so as to extend outward therefrom and coverthe sides of the seat and back structure. By virtue of the compacted triple thickness marginal strip 22, `the outer edge of the latter may be successfully used to guide the sewing operation, which maybe performed by a sewing machine 34 of any suitable or conventional type. In the sewing operation the formed laminated ,part 20 is arranged on a work-supporting 4table 35 of the sewing machine witlrthe marginal strip 22 overlying the bobbinplate 3 6 aud larranged so that Vthe line of the juncture of the inner edge of the strip 22 and adjacet uncompressed or upholstered area 24 ovelie the orifice 37 provided in the plate 36 forl a sewing needle. Superimposed on the upholstered part 2'0 in position .for the sewing operation is the facing cloth 21 arranged with its edgeoverlying the stri-p `22and directed outward as indicated in Fig. y5. A guide `orfollower 38 of the machine 34 `is positioned adjacent'the outer guide edge of the strip/22, so that `as the latter moves-along "the guide 38 during the sewing operation, the facing cloth 21 is 'stitched-at 39 tothe strip -22ac`curte1ylalong the outer edge of the adjacentuphelstered area "24. T he assembly-is` then arrangedonthe` seat structure and the facing cloth -21- is folded outward "as indicated'in phantom, Fig. 5, so as-to cover the seam 39 and marginal strip 22 to 'complete -a neat-and-attractive `cover structure,

In the usual'instanceemployingcloth or afcomparatively inelastic fabric-for-the cover1la'yer 26, considerable diiculty is experienced, asaforesaid, V4in the avoidance `.of wrinkling or gather-ing oftheexcess cover layer material along the portion of the marginal strip 22 whichistransverse to the'groove's 23. 'Inrder'to 'overcome Vthis diculty while utilizing a press apparatus substantially as described thus far, a rocking press member 40 is provided, Figs. 8-10, which is mounted on a pivotal shaft 41 extending transversely to the ribs 31 and parallel to the transverse portion of the depressed strip 22 to be formed. The shaft 41 is journaled in a bracket 42, supported by the die` plate 30, so as to pivot about its longitudinal axis located below the upper edges of the ribs 31 and endwis'e outward thereof, Figs. A9 and 10.

Inward of the axis of the shaft 41, the rocking press member 40 is provided with an edge-forming element 43 adapted to swing upward to a pressing position level with the upper edges of theribs 33 and arranged to press the Iportion of the strip 22 which extends transversely to the grooves 23 at one edge of the part 20. A similar rocking press member is provided to press the portion of the strip 22 at the opposite edge of the part 20; Adjacent the outer edge of the element 43, a cut-off blade 44 is provided as an upward projection of a plate 45 secured to the memb'er 40. The cut-off blade 44 is arranged so that its uppei edge closely underlies the pressing surface of vthe upper press member 28 when the latter is at its pressing p osition, Fig. 10. Accordingly the blade 44 will pierce and trim the overlying layers of the structure 20 and form the aforesaid outer guide edge of the compacted strip 22. A similar blade will be employed with the lateral `ribs 33, if desired, so .as to trim the outer edges of the corresponding lateral portions of thestrip 22 simultaneously as these are pressed by the ribs 33.

Outward yof the .axis of rthe shaft 41, the rocking member 40 is provided with a plate 46 arranged so that its upper surface is rilush with the pressing surface of the upper press member 28 when the latter is at its pressing position, Fig. l0. Uponupward movement of the press member 28, the `outer plate 4'6 is free to swing upward, whereupon 'the inner edge-pressing element 43 will swing downward to 'the position of Fig. 9. Suitable means, such as a spring, maybe employed 'if desired for yieldngly urging the rocking member `.40 Ato the latter position.

Tn fabrication of thepanel 20, 'the layers 25, 26, 27 :are arranged between the press members 28 and 29 as indicated in Fig. 6,'with the Ycover layer 26 confronting ihe ribs 31, `33. Sufficient excess .material ofthe cover layer 26 is .provided `between the )parallel ribs Aso `as vto hang downward in 'loops 26a, which approximate 'the nal contour of the layer 26 .after `the bonding operation. Upon downward movement of the upper press member 28 `relative to the lower press member 29, the cover layer 26 is progressively pressed into `the overlying padding 25 bythe ribs l31, 33, which ,form the grooves 23 `and parallel lateral `portions ofthe marginal `strip 22 as discussed above. Simultaneously, as the press member 128 descends, the plate 46 engaged by the member 28 is swung downward, causing the element '43 andblade '44 to swing upm/"ard Inasmuch as the vlatter swing upward from an `initial `position below `the kupper edges of the ribs '31 and "33, the spacing between the lower pressing surface of the member 28 andthe element 43 will always be greater than the spacing`between the pressing surface andthe upper edges of theribs 31 and 33, until the final pressing V'position iis reached. Accordingly 'the edgepressing element 43 is moved to 'the nal pressing position in delayed relation with yrespect to corresponding ,relative movement between the ribs 31, 33 and press member 28. As a result, the upward pressure on ,the coverlayer 126 exertediby the'element 43 will-always be less during the press movement'thanthe `corresponding pressure exerted by the'ribs 31 or"`33. As the grooves .23.arefprogressively'frmed and the excess'materialo'f the cover 'layer 264 tends to 'gather and form wrinkles for pleats in 'thetrarsverseportions ,o'f the 'strip"22,"th`e progressively increasing pressure of the element 43tends tosmo'othand't'o distributethe cover material uniform-ly .a'l'ong; the length f the'fstrip 22. Gbjectionable-localized 'gathering *of 5"the cover material #and Ethe `formation rof `wrinkles or pleats are thus avoided.

It is also to be noted that as the element 43 and blade 44 swing upward from the position of Fig. 9 to the pressing position of Fig. 10, these members also swing endwise outward of the ribs 31. In consequence a frictonal drag is exerted by these members on the cover layer 26 tending to pull the same endwise outward as the pressing operation progresses. This frietional drag is enhanced by the upwardly projecting edge of the blade 44 and facilitates the progressive smoothing action of the element 43 to eliminate localized gathering of the excess cover layer 26 alongthe transverse portion of the marginal strip 22.

Iclaim: Y p p l. In a press apparatus for pressing laminated materials comprising a deformable padding layer interposed between backing and'cover layers, upper and lower press members relatively movable vertically toward each other in a pressing action, a plurality ofV groove forming ribs extending generally horizontally and in the same direction onvthe lower press member and being cooperable with the underside of the upper press member to form aplurality of generally parallel grooves and intervening upholstered portions in said materials, a third press member pivotally mounted on said lower press member and having a swinging upper pressing surface adapted to swing in said pressingy action upwardly and in said direction away from the ends of said ribs from a position below the upper edges of said ribs yand adjacent said ends, said pressing surface being cooperable with said underside of the upper press member in said pressing action to compact said material, and means on said upper press member engageable with a portion of said third press member to swing the same in said pressing action.

2. in a press apparatus for pressing laminated materials comprising a deformable padding layer interposed between backing and cover layers, upper and lower press members relatively movable vertically toward each other in av pressing action, a plurality of generally parallel horizontal groove forming ribs on the lower press member, said ribs extending generally in a predetermined direction and being cooperablewith the underside of the upper press member to form a plurality of generally parallel grooves and intervening upholstered portions in said materials, a third press member pivo-tally mounted on the lower press member and having a swinging upper pressing surface located below the upper edges of said ribs adjacent the ends thereof adapted to swing upwardly and in said direction away from said ribs in ,said pressing action and being cooperable with said underside of said upper press member in said pressing action to compact said material, the pivot axis of said third press member extending transversely of said ribs at a location below the positions of said pressing surface during said pressing action and spaced from said ribs in said direction from said ends, and kmeans on said upper press member en gageable with a portion of said third press member to 'l swing the same in said pressing action.

3. A press apparatus according to claim 2 wherein said last named means and portion of said third press ymember comprise extensions of said upper press member and third member spaced in said direction from said ribs by said axis and engageable with each other upon vertical movement of said upper and lower press members in said pressing action.

' 4. In a press apparatus for pressing laminated materials comprising a deformable padding layer interposed be- 'tween foundation and cover layers, first and second press members having confronting pressing surfaces and movable relatively toward each other in a pressing operation to press said materials, the first press member having a plurality of parallel groove forming ribs extending generally in one direction and cooperable with the pressing surface of the second press member to form a plurality of generally parallel grooves and intervening upholstered portions in saidv materia1s,.and a third press member pivotally` mounted on said rstpressjmember and having an edge extending transversely of said ribs,`said third press memberu being a-dapted ,tofswin'g'said edge .in said press ing action generally in said direction and toward the pressing surface. of-the second press member andV being cooperable with the latter pressing surface to compact said materials.'

5. In aV press apparatus for pressing laminated materials comprisingv a deformable padding layer interposed between foundation and cover layers, first and second press members having confronting surfaces and movable: relatively toward each other in a pressing operation to`l press said materials, the first press member having a:

plurality of parallel groove forming ribs extending gen-v erally in one direction, said ribs having pressing edgesintermediate said surfaces and cooperable with the sur-- face of the second press member to form a plurality ofv generally parallel grooves and intervening upholstered portions in said materials, and a third press member havingean edge extending transversely of said ribs adjacent their outer terminal ends at a location intermediate said pressing edges and the surface of the rst press member, said third press'member 'being pivotally mounted on said first press member and adapted to swing said edge in said pressing action generally in saidrdirection endwise of said ribs and toward the surface of the second press member and being cooperable with the latter surface to compact said materials.

6. Inl a press apparatus for pressing laminated materials comprising a deformable padding layer interposed between foundation 'and cover layers, a pair of opposed press members movable Vrelatively toward each other in a pressing operation to press said materials therebetween, said press members having cooperating groove forming portionsetfective to form a plurality of generally parallel grooves extending in one direction and spaced by intervening upholstered portions in said materials, a third press member fu-lcrumed between its ends on one of said pair of ,press members, one of said ends being cooperable with the other of said pair of press members in said pressing operation to compact said materials, the other of said ends being engageable with said other of said pair of press members in said pressing operation to swing said one end, said third press member being located between said pair of press members with said ends confronting said other press member, and the fulcrum axis of said third press member extending transversely of said direction and also transversely of the direction of relative movement of said pair of press members.

References Cited in the le of this patent UNITED STATES PATENTS 900,276 Geffers Oct. 6, 1908 1,585,642 Bello May 25, 1926 2,166,435 Haberstump July 18, 1939 2,325,986 Swain et al Aug. 3, 1943 2,326,623 Crosby Aug. 10, 1943 2,500,895 Davies Mar. 14, 1950 2,504,874 Prance Apr. 18, 1950 2,517,069 Weymouth vAug. 1, 1950 2,531,299 Sawyer Nov. 21, 1950 2,541,544 Rahaim Feb. 13, 1951 2,543,582 Lyijynen- Feb. 27, 1951 2,573,466 Lyijynen Oct. 30, 1951 FOREIGN PATENTS 363,509 Germany Nov. 10, 1922 

